Vacuum cleaner equipped with motor exhaust system

ABSTRACT

A vacuum cleaner includes a housing having a nozzle assembly and a canister assembly. A suction inlet is carried on the housing. A dirt collection vessel is carried on the housing. A suction generator is carried on the housing. In addition, the vacuum cleaner includes a motor exhaust assembly. The motor exhaust assembly includes a motor enclosure having a first cavity receiving at least a portion of the suction generator and a filter element received over the motor enclosure.

This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/021,773 filed on 17 Jan. 2008.

TECHNICAL FIELD

The present invention relates generally to the vacuum cleaner art and, more particularly, to a vacuum cleaner equipped with a unique motor exhaust system.

BACKGROUND OF THE INVENTION

A vacuum cleaner is an electromechanical appliance utilized to effect the dry removal of dust, dirt and other small debris from carpets, rugs, fabrics or other surfaces in both domestic and industrial locations. To achieve the desired dirt and dust removal, a pressure drive or “vacuum”, is used to force air entrained with dirt and dust into the suction inlet on the nozzle of the vacuum cleaner. The particulate-laden air is then drawn through a dirt collection vessel such as a bag like filter or dirt cup which traps the dirt and dust, while the substantially clean air is exhausted by an electrically operated fan that is driven by an onboard motor. It is this fan and motor arrangement that generates the drop in air pressure necessary to provide the desired cleaning action. Thus, the fan and motor arrangement is commonly known as the suction generator.

As should be appreciated, the ability of the vacuum cleaner to efficiently and effectively pull air through the nozzle and create the desired suction is a critical factor in determining the level of cleaning power for the vacuum cleaner. The present invention relates to a vacuum cleaner incorporating a unique motor exhaust system or assembly that provides good cooling of the suction generator motor and smooth, clean and efficient air flow through a final filter before exhausting air from the vacuum cleaner into the environment.

SUMMARY OF THE INVENTION

In accordance with the purposes of the present invention as described herein, a vacuum cleaner is provided comprising a housing including a nozzle assembly and a canister assembly, a suction inlet carried on the housing, a dirt collection vessel carried on the housing, a suction generator carried on the housing and a motor exhaust assembly. The motor exhaust assembly includes (1) a motor enclosure having a first cavity receiving at least a portion of the suction generator and (2) a filter element received over that motor enclosure.

More specifically, the motor enclosure comprises a body including an open end, a closed end and at least one side-wall. A series of air flow apertures are provided in the at least one side wall. The closed end includes a first mount engaging the suction generator. Similarly, the at least one side-wall includes a second mount engaging the suction generator. The body may be cylindrical in shape.

The suction generator includes an outer cylindrical housing having an outer diameter D₁ and the second mount has an inner diameter D₂ where D₁ substantially equals D₂ in order to provide a friction fit for holding the motor exhaust assembly on the suction generator housing.

The filter element includes a frame holding a filter media. Further the filter element includes a second cavity receiving the motor enclosure. In one possible embodiment the filter element is cylindrical and has a first open end and a second closed end. The motor enclosure is concentrically received in the second cavity of the filter element. A third and fourth mount secure the filter element to the motor enclosure.

In one possible embodiment the third mount comprises a mounting lug provided on the second closed end of the filter element wherein the mounting lug is sized and shaped to engage the motor enclosure. In this embodiment the fourth mount is an elastomeric mounting ring extending between the filter element and the motor enclosure.

In another possible embodiment both the third and fourth mounts are elastomeric mounting rings extending between the filter element and the motor enclosure to hold the filter element concentrically around the motor enclosure.

In yet another possible embodiment a fastener is provided to secure the filter element over the motor enclosure. More specifically, the body of the motor enclosure includes a series of lugs radially arrayed around the sidewall. In addition, the filter element includes a cooperating series of locking tabs radially arrayed around the frame. The series of locking tabs are engaged with the series of lugs in order to secure the filter element to the motor enclosure.

In accordance with yet another aspect of the present invention, a method is provided for improving the noise suppression and vibration damping of a vacuum cleaner motor. The method includes the steps of (a) placing a motor enclosure over at least a portion of the suction generator and (b) placing a filter element over the motor enclosure.

In the following description there is shown and described possible embodiments of this invention, simply by way of illustration of some of the modes best suited to carry out the invention. As it will be realized, the invention is capable of other different embodiments and its several details are capable of modification in various, obvious aspects all without departing from the invention. Accordingly, the drawings and descriptions will be regarded as illustrative in nature and not as restrictive.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings incorporated in and forming a part of the specification, illustrate several aspects of the present invention and together with the description serve to explain certain principles of the invention. In the drawings:

FIG. 1 is a perspective view of an upright vacuum cleaner of the present invention;

FIG. 2 is a detailed partially exploded perspective view of the suction generator and motor exhaust assembly;

FIG. 3 is a detailed cross-sectional view illustrating the suction generator received in a first embodiment of the motor exhaust assembly;

FIG. 4 is a detailed cross-sectional view illustrating the suction generator received in a second embodiment of the motor exhaust assembly; and

FIGS. 5A and 5B are perspective views illustrating yet another alternative embodiment of the present invention wherein the body of the motor enclosure includes a series of lugs and the frame of the filter element includes a series of locking tabs wherein the tabs and lugs are engaged to secure the motor enclosure and filter element together.

Reference will now be made in detail to the present preferred embodiments of this invention, examples of which are illustrated in the accompanying drawings.

DETAILED DESCRIPTION OF THE INVENTION

Reference is now made to FIG. 1 showing the upright vacuum cleaner 10 of the present invention. The upright vacuum cleaner 10 includes a housing comprising a nozzle assembly 14 and a canister or handle assembly 16. The handle assembly 16 includes a control handle 18 and a handgrip 20. A control switch 22 is provided for turning the vacuum cleaner 10 on and off. Of course, electrical power is supplied to the vacuum cleaner 10 from a standard electrical wall outlet through an electrical cord (not shown). Alternatively, the vacuum cleaner 10 could be powered by battery if desired.

A pair of rear wheels (not shown) are provided on the lower portion of the handle assembly 16 and a pair of front wheels (also not shown) are provided on the nozzle assembly 14. Together, these wheels support the vacuum cleaner 10 for movement across the floor. To allow for convenient storage of the vacuum cleaner 10, a foot latch 30 functions to lock the canister assembly in an upright position as shown in FIG. 1. When the foot latch 30 is released, the handle assembly 16 may be pivoted relative to the nozzle assembly 14 as the vacuum cleaner 10 is manipulated back and forth to clean the floor.

In the presently illustrated embodiment, the handle assembly 16 includes a cavity adapted to receive and hold the dirt collection vessel 32. As illustrated in FIG. 2, the dirt collection vessel 32 may take the form of a dirt cup and lid 34 including a cylindrical sidewall 36, a tangentially directed inlet (not shown) and an axially directed outlet 40. A primary filter 42 may be provided in the dirt cup 34 over the axially directed outlet 40. The primary filter 42 is cylindrical in shape and concentrically received within the cylindrical sidewall 36 of the dirt cup 34. Such a structural arrangement induces cyclonic airflow in the dirt cup 34 and provides for enhanced cleaning efficiency. In an alternative design, the handle assembly 16 includes a closed compartment that houses a filter or vacuum cleaner bag, of a type known in the art, that functions as the dirt collection vessel 32.

The nozzle assembly 14 includes a suction inlet 44. A rotary agitator 46 is carried on the nozzle assembly 14 so as to extend across the suction inlet 44. A suction generator 48, including a fan and a cooperating drive motor, is carried on the handle assembly 16. The suction generator 48 functions to generate a vacuum air stream for drawing dirt and debris from the surface to be cleaned. The rotary agitator 46 is connected by power take off to the motor of the suction generator 48. While the suction generator 48 is illustrated as being carried on the handle assembly 16, it should be appreciated that, alternatively, it could be carried on the nozzle assembly 14 if desired.

During normal vacuum cleaner operation, the rotary agitator 46 is driven by the motor of the suction generator 48 and functions to beat dirt and debris from the nap of an underlying carpet. The suction generator 48 functions to draw a vacuum air stream into the suction inlet 44. Dirt and debris from the carpet is entrained in the air stream, which is then drawn by the suction generator 48 into the dirt cup 34. Dirt and debris is captured in the dirt cup 34 while relatively clean air is drawn through the primary filter 42. That air stream then passes over the motor of the suction generator 48 to provide cooling before being exhausted through a final filter 56, such as a HEPA filter, before being exhausted through an exhaust port 38 into the environment (see also FIGS. 2 and 3).

As best illustrated in FIGS. 2 and 3, the suction generator 48 is held in the canister or handle assembly 16 in a motor exhaust assembly, generally designated by reference number 50. This first embodiment of the motor exhaust assembly 50 includes a motor enclosure 52 in the form of a cylindrical body having a first cavity 54 for receiving at least a portion (i.e. the exhaust end) of the suction generator 48 and a filter element 56 received over the motor enclosure.

The motor enclosure 52 includes a body having an open end 58, a closed end 60 and at least one side-wall 62. The closed end 60 includes a first mount, illustrated as mounting tabs 64, for engaging an end of the suction generator 48. As illustrated, the side-wall 62 includes a second mount 66 for engaging the suction generator 48. More specifically, the second mount 66 comprises a portion of the body of the motor enclosure 52. The suction generator 48 also includes an outer cylindrical housing 68 having an outer diameter D₁. The second mount 66 has an inner diameter D₂ where D₁ substantially equals D₂. Accordingly, a friction fit is provided by the first and second mounts 64, 66 with the housing 68 of the suction generator 48 at two different points adjacent the ends the motor enclosure 52.

As further illustrated in FIGS. 2 and 3, the filter element 56 includes a frame 70 holding a filter media 72 of a type known in the art for the purposes of filtering dirt and debris from an air stream of a vacuum cleaner. As illustrated, the filter element 56 includes a second cavity 74 for receiving the motor enclosure 52. The filter element 56 is substantially cylindrical and has a first open end 76 and a second closed end 78. As best illustrated in FIG. 3 the motor enclosure 52 is concentrically received in the second cavity 74 of the filter element 56.

More specifically, the first embodiment of the motor exhaust assembly 50 includes third and fourth mounts 80, 82. Each mount 80, 82 comprises an elastomeric mounting ring sized and shaped to extend between the frame 70 of the filter element 56 and the body of the motor enclosure 52. The mounting rings 80, 82 function to provide a friction fit between the motor enclosure 52 and filter element 56. Further, the fourth mount 82 effectively seals the open end 76 of the filter element 56 so as to form an annular exhaust manifold 84 between the filter media 72 of the filter element 56, the side-wall 62 of the motor enclosure 52 and the two mounting rings 80, 82. Thus, as illustrated in FIG. 3 air is drawn into the suction generator 48 through the inlet (note action arrow A). That air then passes over the motor of the suction generator 48 providing cooling. The air is then discharged through the airflow apertures 86 provided in the side-wall 62 of the motor enclosure 52 (note action arrows B). The air then passes from the exhaust manifold 84 through the filter media 72 of the filter element 56 (note action arrows C). The airflow apertures 86 in the sidewall 62 of the motor enclosure 52 and the annular exhaust manifold 84 function together to provide a radial air flow exhaust path from the suction generator 48 and the motor exhaust assembly 50. This results in consistent, even motor cooling and more efficient air flow movement than possible with other designs. At the same time, any residual dirt, debris and particulates in the air stream including, for example, any carbon from the brushes of the motor of the suction generator 48 are captured by the filter media 72. The resulting clean air is then exhausted from the vacuum cleaner 10 through the exhaust ports 3 8 (see FIG. 1).

A second, alternative embodiment of the motor exhaust assembly 50 is illustrated in FIG. 4. In this embodiment the third mount 80 comprises a mounting lug 88 that projects inwardly from the closed end 78 of the filter element 56. The lug 88 may be continuous or interrupted and is sized and shaped to engage in friction fit with the end of the sidewall 62 of the motor enclosure 52. The structure of the motor exhaust assembly 50 is otherwise unchanged and like parts are identified by the same reference numbers used for the first embodiment illustrated in FIGS. 2 and 3.

In yet another alternative embodiment illustrated in FIGS. 5A and 5B the sidewall 62 of the motor enclosure 52 includes a series of lugs 90 that project radially and outwardly. The frame 70 of the filter element 56 includes a series of cooperating locking tabs 92. As illustrated in FIG. 5A, the filter element 56 is positioned over the sidewall 62 of the motor enclosure 52 with the locking tabs 92 adjacent the lugs 90. The filter element 56 is then rotated or twisted relative to the motor enclosure 52 in the direction of action arrow Z to engage the series of tabs 92 and lugs 90 (see FIG. 5B). This secures the filter element 56 to the motor enclosure 52.

In summary, any of the embodiments of the present invention provide a motor exhaust assembly 50 incorporating a motor enclosure 52 and filter element 56 that are cooperatively connected together and receive the suction generator 48 in a manner that ensures superior sound suppression, superior vibration damping and smooth and efficient air flow to maximize suction generator efficiency while also ensuring all particulates are captured before the air stream is exhausted back into the environment. Any of the embodiments may also be used in a method to improve noise suppression and vibration damping of a vacuum cleaner motor. This is done by placing a motor enclosure over at least a portion (i.e. the exhaust end) of the suction generator and placing a filter element over the motor enclosure.

The foregoing description of the preferred embodiments of the invention have been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Obvious modifications or variations are possible in light of the above teachings. The embodiments were chosen and described to provide the best illustration of the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the invention as determined by the appended claims when interpreted in accordance with the breadth to which they are fairly, legally and equitably entitled. The drawings and preferred embodiment do not and are not intended to limit the ordinary meaning of the claims and their fair and broad interpretation in any way. 

1. A vacuum cleaner, comprising: a housing including a nozzle assembly and a canister assembly; a suction inlet carried on said housing; a dirt collection vessel carried on said housing; a suction generator carried on said housing; and a motor exhaust assembly including (a) a motor enclosure having a first cavity receiving at least a portion of said suction generator and (b) a filter element received over said motor enclosure.
 2. The vacuum cleaner of claim 1, wherein said motor enclosure comprises a body including an open end, a closed end and at least one sidewall.
 3. The vacuum cleaner of claim 2, wherein a series of airflow apertures are provided in said at least one sidewall.
 4. The vacuum cleaner of claim 3, wherein said closed end includes a first mount engaging said suction generator.
 5. The vacuum cleaner of claim 4, wherein said at least one sidewall includes a second mount engaging said suction generator.
 6. The vacuum cleaner of claim 5, wherein said body is cylindrical.
 7. The vacuum cleaner of claim 6, wherein said suction generator includes an outer cylindrical housing having an outer diameter D₁ and said second mount has an inner diameter D₂ where D₁ substantially equals D₂ to provide a friction fit.
 8. The vacuum cleaner of claim 7, wherein said filter element includes a frame holding a filter media.
 9. The vacuum cleaner of claim 8, wherein said filter element includes a second cavity receiving said motor enclosure.
 10. The vacuum cleaner of claim 9, wherein said filter element is cylindrical and has a first open end and a second closed end.
 11. The vacuum cleaner of claim 10, wherein said motor enclosure is concentrically received in said second cavity of said filter element.
 12. The vacuum cleaner of claim 11, further including a third mount and a fourth mount securing said filter element to said motor enclosure.
 13. The vacuum cleaner of claim 12, wherein said third mount comprises a mounting lug provided on said second closed end of said filter element wherein said mounting lug is sized and shaped to engage said motor enclosure and said fourth mount is an elastomeric mounting ring extending between said filter element and said motor enclosure.
 14. The vacuum cleaner of claim 12, wherein said third and fourth mounts comprise two elastomeric mounting rings extending between said filter element and said motor enclosure to hold said filter element concentrically around said motor enclosure.
 15. The vacuum cleaner of claim 11, further including a fastener to secure said filter element over said motor enclosure.
 16. The vacuum cleaner of claim 11, wherein said body includes a series of lugs radially arranged around said at least one sidewall.
 17. The vacuum cleaner of claim 16, wherein said filter element includes a series of locking tabs radially arrayed around said frame wherein said series of locking tabs engages said series of lugs to secure said filter element to said motor enclosure.
 18. A method of improving noise suppression and vibration damping of a vacuum cleaner motor, comprising: placing a motor enclosure over at least a portion of said suction generator; and placing a filter element over said motor enclosure. 